Multiphasic liquid flow as a universal tool for nanofabrication of diverse polymer morphologies

Abstract Soft matter of synthetic and biological origin find application in a range of consumer products such as rheological modifiers, structural adhesion enhancers, nonwovens, and membranes1. The functionality of materials typically derives from their nano- and microscale structure and overall morphology1-3. Many fabrication techniques are capable of producing morphologies including particles4, fibers4,5, and membranes6,7. Yet, these techniques may be limited in producing a few specific morphologies and in fine-tuning nano- or microscopic features. Many are also resource and energy-intensive, restricting their potential as commercial processes8. Here, we explore interfacial polymer precipitation within sheared multiphasic systems. Through systematic investigation of critical processing parameters, we observe the fabrication of twelve unique polymer morphologies. We verify that the liquid shear-based technique is versatile and works well with chemically diverse polymers, showing potential as a universal tool for fabricating many morphologically distinct polymer structures by simple, scalable processes.